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Fluid Bed Processor (FBD)

Fluid Bed Processor (FBD)

₹4,000,000.00

A Fluid Bed Processor (FBD) is a versatile and efficient equipment for coating, granulation, and drying in pharmaceutical production. Due to its quick processing rate, accurate control, and consistent product quality, it is used extensively for tablet, capsule, and pellet production.

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Fluid Bed Processor (FBD) – Technical Specification & Application in the Pharmaceutical Industry

Fluid Bed Processor (FBD) is a universal machine employed in pharmaceutical production to dry, granulate, and coat powders and granules. It functions on the principle of suspending particles in a hot air stream, providing effective heat transfer, uniform drying, and controlled size distribution of particles.

Technical Specifications of Fluid Bed Processor (FBD)

  1. Construction Material
    • Stainless Steel (SS 316L for product contact items, SS 304 for non-contact items) – meets GMP & FDA standards.
    • Mirror or Matte Finish – aids easy cleaning and avoids contamination.
    • Anti-Static Filters – avoids static charge accumulation in fine powders.
  1. Processing Capacity

Available in 1 kg (lab-scale) to 1000 kg (industrial-scale) per batch.

  1. Air Handling & Heating System
    • Primary Air Blower: Provides uniform fluidization of particles.
    • HEPA Filters (H13 or H14): Eliminates airborne impurities, providing a hygienic processing area.
    • Heating Source:
    • Electrical Heater (for laboratory or small-scale applications).
    • Steam / Hot Water / Gas Heaters (for commercial production).
    • Temperature Control: 30°C – 120°C, adjustable through PLC-based controllers.
  1. Spray System (For Granulation & Coating)
    • Top Spray: Applied to granulation & drying processes.
    • Bottom Spray (Wurster Process): For coating pellets and tablets.
    • Tangential Spray: Applied to agglomeration and layering processes.
    • Spray Nozzle Size: 0.5–2.0 mm for accurate atomization.
  1. Filter & Exhaust System
    • Bag/Cartridge Filters with Automatic Shaking Mechanism – avoids powder loss.
    • Exhaust Blower (CFM Range 500–3000 CFM) – proper airflow and dust management.
  1. Control System
    • PLC-Based HMI Touchscreen Panel – automatic process control.
    • Real-Time Monitoring: Regulates inlet air temperature, airflow, spray rate, and drying time.
    • Batch Recipe Storage: Enables consistent processing parameters.
  1. Safety Features
    • Explosion-Proof Design – optional for solvent-based granulation.
    • Pressure Relief Dampers – avoids damage due to overpressure.
    • Fire Detection & Suppression System (Optional) – for use with flammable substances.
    • Earthing & Static Charge Protection – to protect operators.

Applications of Fluid Bed Processor (FBD) in the Pharmaceutical Industry

  • Drying of Wet Granules: Quick drying of wet granules following high-shear granulation prior to tablet compression. More effective compared to conventional tray drying.
  • Granulation (Top Spray Method): Transforms powders into granules with the use of a binder solution spray.
  • Enhances flowability and compressibility for tablet production.
  • Coating of Pellets & Granules (Bottom Spray – Wurster Process)
  • Utilized in controlled-release drug delivery products.
  • Deposits polymeric coatings for sustained or delayed release capsules and tablets.
  • Agglomeration & Instantization (Tangential Spray Method)
  • Creates dust-free, free-flowing granules for instant powders (e.g., infant formula, protein powders).
  • Multi-Industry Applications: Applied in pharmaceutical, food, nutraceutical, chemical, and herbal industries.

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FAQs

What is a Fluid Bed Processor (FBD)?
A Fluid Bed Processor is a multifunctional system used to dry, granulate, or coat powders and granules by suspending them in an upward flow of heated air. This fluidization allows for efficient heat and mass transfer, resulting in uniform processing.
What are the main applications of an FBD in pharma?
Drying: Moisture removal from wet granules post-wet granulation Granulation: Using a binder solution sprayed onto fluidized powders Coating: Applying functional or protective layers onto granules or pellets Top spray, bottom spray (Wurster), and tangential spray configurations
What are the core components of an FBD?
Product container (bowl) Air handling unit (blower, heater, filters) Expansion chamber with filters (finger bags or bowl filters) Spray system (top, bottom, or tangential spray nozzles) Control panel (HMI/PLC) Exhaust system with HEPA filters Product discharge system Optional WIP (Wash-in-Place) system
What is the working principle of an FBD?
Heated air is passed through a perforated bottom plate Powders are fluidized and suspended in the airflow For granulation or coating, a binder or coating solution is sprayed Airflow and temperature are precisely controlled for uniform processing
What is the difference between FBD drying and granulation?
Drying: No liquid spray; used to remove moisture from wet granules Granulation: A binder solution is sprayed onto fluidized powder to form granules Coating: Solution is sprayed onto fluidized pellets or granules to form a uniform layer
What are the typical batch sizes for FBDs?
Lab scale: 0.5–5 kg Pilot scale: 5–30 kg Production scale: 30–600+ kg Batch size flexibility often ranges from 30–100% of nominal capacity
What are the construction materials and finishes?
Product contact parts: SS 316/316L Non-contact parts: SS 304 Gaskets and seals: FDA-grade EPDM, silicone, or PTFE Surface finish: Mirror polish or Ra ≤ 0.5 µm inside
What control features are available?
PLC with HMI touchscreen interface Temperature, airflow, and spray rate control 21 CFR Part 11 compliance (audit trail, password protection) Recipe management and batch recording Integrated WIP systems (optional)
What types of filters are used in an FBD?
Product filters: Finger bags or bowl-type filter elements Inlet air filters: Pre-filter, fine filter, and HEPA filter (H13/H14) Exhaust filters: HEPA filter to prevent contamination release Automatic or manual bag shaking systems are used for cleaning
What safety features are included?
Explosion relief vents or flameless venting (ATEX compliance) Temperature and pressure alarms/interlocks Earth bonding and anti-static filters Flameproof motors (if processing solvent-based materials) Emergency stop buttons and interlocks
How is cleaning and validation done?
Manual cleaning through access doors (smaller models) WIP/CIP options with spray nozzles and drain valves Validation includes: IQ/OQ/PQ protocols Airflow and temperature uniformity mapping Spray pattern validation Cleaning validation (swab/rinse tests, TOC analysis)
What are the differences between FBD, Fluid Bed Granulator, and Fluid Bed Coater?
Type Function Spray System FBD Dryer Drying only No spray Fluid Bed Granulator Wet granulation Top spray Fluid Bed Coater Coating pellets/granules Bottom or tangential spray (Wurster)
What are common issues and troubleshooting tips?
Issue Cause Solution Uneven drying Poor fluidization or overloaded batch Adjust airflow/load Filter choking Dust or sticky materials Clean filters regularly, use WIP Granule lumping Over-spraying or low airflow Optimize spray rate & air volume Spray nozzle clogging Improper cleaning or suspension Use proper nozzle size & cleaning SOPs
What standards and regulations does it comply with?
cGMP (21 CFR Part 210/211) FDA 21 CFR Part 11 (for software and records) EU GMP Annex 11 ATEX directives (for explosive environments) ISPE and GAMP 5 guidelines

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